Electric Brakes Adjustment

Brake Adjustment

Brakes should be adjusted (1) after the first 200 miles (322 Km) of operation when the brake shoes and drums have “seated”, (2) at 3,000 miles (4,827 Km) intervals, (3) or as use and performance requires. The brakes should be adjusted in the following manner:

1.Jack up trailer and secure on adequate capacity jack stands. Follow trailer manufacturer’s recommendations for lifting and supporting the unit. Make sure the wheel and drum rotates freely.

Caution:

Do not lift or support trailer on any part of the axle or the suspension system. Never crawl under your trailer unless it is resting on properly placed jack stands.

2.Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate.

3.With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn.

Note: For drop spindle axles, a modified adjusting tool may be necessary.

4.Then rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag.

5.Replace the adjusting hole cover and lower the wheel to the ground.

6.Repeat the above procedure on all brakes. For best results, the brakes should all be set at the same clearance.

BRAKEMASTER ™

PART # 20001, #20002, #20003 ✱ and #20004 ✱

Break-Away System for Single, Tandem, and Tri-Axle Trailers

“Safety on the road”

Make sure you have all parts before you start your installation.

✱ Kits #20003 and #20004 do not include mounting hardware.

MOUNTING HARDWARE

Break-Away Box (2) U-Bolts

(4) Locking Nuts (4) Self-Tap Screws (4) Small Flat Washers Break-Away Switch with Cable

The Break-Away System is designed to bring trailers safely to a stop by activating electric brakes, should a trailer be disconnected while driving. This type of safety system is required in most states on trailers rated over 3,000 GVW. The following instructions must be precisely followed to ensure proper operations. Please read the following instructions thoroughly before installing this product. Your trailer must have operational electric brakes before installation. Once you determine your trailer brakes work, find a secure location on your trailer to mount the Break-Away Kit. You have two options to mount this kit

OPTION 1-

U-BOLT MOUNTING INSTRUCTIONS:

1.Use included U-Bolts and wrap around secure mounting surface on trailer (jack, frame, etc.).

2.Attach Break-Away Kit by routing U-Bolts through holes provided on each side of the plastic casing.

3.Place one flat washer over each bolt with locking nut. Use 1/2” wrench and tighten. Note: Be careful not to over tighten. Over tightening may cause housing to crack.

4.Next mount Break-Away Switch close enough on trailer that cable can be attached to vehicle.

5.Follow “Wiring Installations”.

OPTION 2SELF-TAPPING SCREW MOUNTING INSTRUCTIONS:

1.Locate secure surface on trailer to mount Break-Away Kit.

2.With flat washers on each screw, route through provided holes in each corner of the BreakAway Kit plastic casing. Use screwdriver or drill and secure to trailer. DO NOT drill holes in trailer frame. This will weaken the frame and void your trailer warranty.

3.Next mount Break-Away Switch close enough on trailer that cable can be attached to vehicle.

4.Follow “Wiring Installations”.

WIRING INSTRUCTIONS:

PIN

CABLE SAFETY CHAIN POCKET BUMPER CLEVIS

BREAK-AWAY SWITCH

BREAKAWAY

BREAK-AWAY SWITCH CABLE CABLE

1.Splice one blue wire of the Break-Away Switch to the electric brake wire coming from the trailer side connector (A).

2.Connect other blue wire of Break-Away Switch to the blue wire (labeled “Brake”) from the Break-Away Box (B). (Note: Blue wires are interchangeable on the Break-Away Switch.)

3.Splice white wire from Break-Away Box to existing ground wire on trailer or ground directly to trailer frame (C).

4.Splice black wire on Break-Away Box to trailer 12-Volt auxiliary power lead (D). This will charge the Break-Away battery when vehicle is in use. (Note: Black wire is found only on Model 20001 and 20004.)

5.Test unit by pulling firmly on cable of Break-Away Switch. Battery will activate brakes. (Note: Do not use this kit as a parking brake.) Battery should be charged and tested prior to each trailer outing.

OPERATING INSTRUCTIONS:

1.Test your Break-Away Kit before each outing as described in Step 5 of the wiring instructions.

2.Once tested, Break-Away Switch cable should be secured to vehicle bumper or frame. The cable can be attached many different ways. Two of the most common are: (1) Pull the pin out of the Break-Away Switch (Fig. 1) and route through safety chain pocket (Fig. 2), then through cable loop and reconnect pin. (2) Attach cable loop to a bumper clevis (Fig. 3). Do not loop cable over hitch ball, cable may bounce off while vehicle is moving. Note: Plunger pin must be facing the rear of the vehicle directly behind where you secure the cable on your vehicle. Any other angle may cause Break-Away Switch failure.

Break-Away Kit Accessories

#20005 Break-Away Switch Complete with Cable

#20006 Box and Hardware

#20009 Replacement Break-Away Switch Cable and Pin

#20007 Break-Away Kit Charger

YOUR TRAILER MUST HAVE OPERATIONAL ELECTRICAL BRAKES TO USE THIS PRODUCT.

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DIAGRAM WITH CHARGER (Part No’s. 20001 & 20004)

DIAGRAMA CON EL CARGADOR (Núm. de Partes 20001 & 20004)

DIAGRAMME AVEC CHARGEUR (N os de pièce 20001 et 20004)

Electric Brake (Blue)

Freno Eléctrico (Azul)

Frein électrique (bleu)

Ground (White)

Conexión a Tierra (Blanco) Masse (blanc)

12-Volt Battery Lead (Black or Red)

Conductor de batería de 12 voltios (Negro o Rojo)

Conducteur de batterie de 12 volts (noir ou rouge)

White / Blanco / Blanc

■ A, B, C and D are splices

A, B, C y D son empalmes

A, B, C et D sont des épissures

Black Negro Noir

Blue / Azul / Bleu

Blue

Azul

Bleu

Break-Away Box / Caja Break-Away / Boîtier Break-Away

DIAGRAM WITHOUT CHARGER (Part No’s. 20002 & 20003)

DIAGRAMA SIN EL CARGADOR (Núm. de Partes 20002 & 20003)

DIAGRAMME SANS CHARGEUR (N os de pièce 20002 et 20003)

Electric Brake (Blue)

Freno Eléctrico (Azul)

Frein électrique (bleu)

Break-Away Switch

Interruptor Break-Away

Interrupteur Break-Away

Cable / Cable / Câble

Blue / Azul / Bleu

Ground (White)

Conexión a Tierra (Blanco)

Masse (blanc)

White / Blanco / Blanc

■ A, B and C are splices

A, B, y C son empalmes

A, B, et C sont des épissures

Blue

Azul

Bleu

Break-Away Switch

Interruptor Break-Away

Interrupteur Break-Away

Cable / Cable / Câble

Break-Away Box / Caja Break-Away /. Boîtier Break-Away

Note: Wire By Function Only. Color Coding is Not Standard Among Manufacturers.

Nota: Instale el cableado por su función solamente. Código de color no es la norma entre todos los fabricantes.

Remarque: Câbler uniquement selon les fonctions. Le code de couleur peut varier d’un constructeur à l’autre.

QUESTIONS - CALL / PREGUNTAS - LLAME AL / QUESTIONS - APPELER AU 1-800-835-0129